Mercedes-Benz 463 series Introduction Into Service Manual
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Mercedes-Benz 463 series Introduction Into Service Manual

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Introduction of the New G-Class
Model series 463
Introduction into Service Manual
– This printout will not be recorded by the update service. Status: 03 / 2012 –

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Summary of Contents for Mercedes-Benz 463 series

  • Page 1 Introduction of the New G-Class Model series 463 Introduction into Service Manual – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 2 Mercedes-Benz Service Introduction of the New G-Class Model series 463 Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 3 Information and copyright Product Portfolio Comprehensive information about our full Product Portfolio can also be found at our Internet Portal. Link: http://aftersales.mercedes-benz.com Questions and suggestions If you have any questions or suggestions concerning this product, please write to us. E-mail: customer.support@daimler.com...

  • Page 4: Table Of Contents

    Contents Preface Overview Models and major assemblies Brief description Equipment Overall vehicle Exterior Dimensions of G 350 BLUETEC Dimensions of G 63 AMG Technical data Roof systems Interior Powerplant Engine data for gasoline engines Engine data for diesel engines Gasoline engines M 157 AMG and M 273 Diesel engine OM 642 Engine cooling Exhaust system...
  • Page 5 Contents Chassis Steering Axles Suspension On-road/off-road characteristics Brake system Wheels and tires Networking Overall network Batteries and alternator Lights Exterior lights Interior lights Safety Active/passive safety Restraint systems Driving assistance systems Overview of systems Comfort Climate control Introduction of the New G-Class, Model Series 463 –...
  • Page 6 Contents Audio and communications Telematics Sound system Digital Owner's Manual Body Bodyshell Annex Abbreviations Index Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...

  • Page 7: Preface

    WIS. The contents of this brochure are not assumed here that the reader is already familiar with updated. No provision is made for supplements. the Mercedes-Benz model series currently on the We will publicize modifications and new features in the market.

  • Page 8: Models And Major Assemblies

    Models and major assemblies Model Engine Automatic Market launch 7-speed transmission G 500 463.202 273.969 722.904 06/12 convertible G 500 463.236 273.969 722.904 06/12 G 350 BLUETEC 463.346 642.886 722.902 06/12 G 550 463.237 273.969 722.904 08/12 G 63 AMG 463.272 157.984 722.905...

  • Page 9: Brief Description

    Brief description Vehicle concept New features The combination of a characteristic and timeless Main features of the model refinement include: design has made the G-Class into an unmistakable • Introduction of the G 63 AMG cross-country vehicle. • ECO start/stop function (G 63 AMG only) The impressive appearance of the facelifted model •...

  • Page 10: Equipment

    Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Equipment variants Exclusive package Code PA4 — — designo Exclusive package — — — Code PA6 Sport package Code PA5 — — Chrome package Code ZD6 Standard Seating comfort package Code PA1 Standard Code PA1...
  • Page 11 Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Wheels, tires, light alloy wheels 45.72 cm (18") light alloy wheel Code RL5 — "5-hole design" 265/60; 7.5 J x 18 ET63 45.72 cm (18") light alloy wheel Code RM9 Standard —...
  • Page 12 Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Light systems Bi-xenon headlamps with automatic head- Standard lamp range adjustment and headlamp cleaning system Oval front fog lamps with integrated corner- Standard — ing lights function LED daytime running lights Standard Headlamp Assist Standard...
  • Page 13 Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Interior equipment Multifunction steering wheel Standard Heated multifunction steering wheel (only in Code VL0 combination with leather steering wheel Leather upholstery, black Code SP3 Standard — Leather upholstery, gray Code SP4 —...
  • Page 14 Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Comfort systems Electrically adjustable front seats incl. Standard 4-way lumbar support Seat heaters for driver and front passenger Standard Heater for rear bench seat Standard Safety and theft protection Airbags for driver and passenger Standard Windowbag...
  • Page 15 Equipment G 350 G 500 G 550 G 63 AMG BLUETEC Telephone, audio and communications HD radio — — Standard Standard Surround sound system Code EU9 Code EU9 Standard Code EU9 ® ® (harman/kardon Logic 7 COMAND Online Standard Digital Audio Broadcasting (DAB) Code EF6 Code EF6 —...

  • Page 16: Exterior

    Exterior Front view The functional, robust front view of the G-Class has The G-Class also features new outside mirrors. These retained its character for decades. produce less aerodynamic drag and provide signifi- cantly improved aeroacoustics. One of the most important features of the front design is the radiator grille with three slats and a large central The radar unit of the Distronic system, optionally avail- star.
  • Page 17 Exterior Side view Clear lines and large flat areas distinguish the side The rub strip runs horizontally along the vehicle level view of the G-Class. The station wagon is character- with the door handles and the distinctly shaped wheel ized by two large windows in the rear. The rocker well liners provide a harmonious overall appearance panels, beltline and roof edges run parallel to each together with the striking and powerful design of the...
  • Page 18 Exterior Rear view The distinct wheel well liners and wide track width give The oval rear lamps in classic rectangular lamp units, the G-Class a robust and sturdy image. The main the rear bumper with integrated rear fog lamp and elements of the rear design include the large left- backup lamp as well as the stainless steel spare wheel hinged rear-end door as well as the full-size spare...

  • Page 19: Dimensions Of G 350 Bluetec

    Dimensions of G 350 BLUETEC P00.10-5198-00 Vehicle dimensions of G 350 BLUETEC Dimensions unloaded 1 At permissible gross vehicle weight Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 20 Dimensions of G 350 BLUETEC P00.10-5199-00 Vehicle dimensions (garage dimensions) of G 350 BLUETEC Dimensions unloaded 1 At permissible gross vehicle weight Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...

  • Page 21: Dimensions Of G 63 Amg

    Dimensions of G 63 AMG P00.10-5200-00 Vehicle dimensions of G 63 AMG Dimensions unloaded Vehicle without license plate adapter (6 mm) 1 At permissible gross vehicle weight Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 22 Dimensions of G 63 AMG P00.10-5201-00 Vehicle dimensions (garage dimensions) of G 63 AMG Dimensions unloaded Vehicle without license plate adapter (6 mm) 1 At permissible gross vehicle weight Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...

  • Page 23: Technical Data

    Technical data Comparison of model series 463 against model series 463 MOPF Unit Difference MOPF2012 Dimensions Vehicle length 4257/4662 4257/4662 Vehicle width 1760 1760 Vehicle width 2007 2055 (with outside mirrors folded out) Vehicle height 1951 1951 Wheelbase 2400/2850 2400/2850 Front overhang Rear overhang Front track width...
  • Page 24 Technical data Unit G 500 con- G 350 G 500/ G 63 AMG vertible BLUETEC G 550 Dimensions and weights Curb weight as per EC 2417 2607 2567/ 2475 2708 Permissible gross vehicle weight 2850 3200 3200 3200 1142 Open luggage compartment volume behind rear seat as per ISO 3832-V211 Maximum luggage compartment...

  • Page 25: Roof Systems

    Roof systems Convertible Sliding roof The electrohydraulic soft top with draft stop as stan- An electrically powered sliding roof is available as dard provides a unique open-top driving experience in special equipment. the G-Class convertible. The semi-automatic soft top can be released easily by hand and it then opens and closes within 30 seconds at the touch of a button.

  • Page 26: Interior

    Interior Interior design A completely redesigned dashboard and a revised The new, clearly arranged instrument cluster features center console further improve the user-friendliness two classic dial-type gauges and a central color multi- of the controls and significantly improve the aesthetic function display with TFT technology.

  • Page 27: Instrument Cluster

    Interior Instrument cluster P54.33-2167-00 Instrument cluster, ECE version Shown on model 463.346 Instrument cluster A1e51 Brake system warning lamp A1e1 Left turn signal indicator lamp A1e54 Coolant temperature warning lamp A1e2 Right turn signal indicator lamp A1e57 Front fog lamp indicator lamp A1e3 High beam indicator lamp A1e58...
  • Page 28 Interior Center console The upper control panel is used to switch the seat The center console is equipped with a new selector heater, ESP off and hazard warning flasher functions lever module with touch shift. on and off. The seat ventilation, parking system and The entertainment and communication systems inte- stationary heater functions are available as special grated in the vehicle can be controlled using the new,...
  • Page 29 Interior Overhead control panel (OCP) The OCP has been redesigned with a new network Depending on the vehicle equipment, the electric structure. The interior and rear lights, all reading sliding roof (SA) or the electric soft top are also lamps for the driver, front passenger and rear (left/ controlled via the OCP.
  • Page 30 Interior Seats The seats of the G-Class are optimized for long Three different materials are available for the seat distances and have numerous comfort functions: upholstery. In the G 350 high-quality, robust fabric coverings are used as standard. • Front seats with electric adjustment of seat fore/ aft position and seat cushion height for high Leather upholstery in gray, black and chestnut can be seating comfort...

  • Page 31: Engine Data For Gasoline Engines

    Engine data for gasoline engines Unit G 500/G 550 G 63 AMG Engine data 273.969 157.984 Engine designation M 273 KE55 M 157 DEH 55LA Engine configuration/no. of cylinders Displacement 5461 5461 Bore Stroke 90.5 90.5 Fuel Premium Super Plus Performance Acceleration 0 ...

  • Page 32: Engine Data For Diesel Engines

    Engine data for diesel engines Unit G 350 BLUETEC Engine data 642.886 Engine designation OM 642 D30 Cylinder arrangement/no. of cylin- ders Displacement 2987 Bore Stroke Fuel Diesel Performance Acceleration 0 ... 100 km/h Maximum speed km/h Fuel economy/CO emissions Fuel economy, overall (NEDC) l/100 km 11.2...

  • Page 33: Gasoline Engines M 157 Amg And M 273

    Gasoline engines M 157 AMG and M 273 The V8 engines M 273 and M 157 AMG are used in i Note model series 463. The AMG engine with replaces the previous M 113 V8 engine. The Introduction into Service Manual "Introduction of the New 8-Cylinder V-Engine The advantages of the M 157 AMG compared to the Generation M 157 AMG"...
  • Page 34 Gasoline engines M 157 AMG and M 273 Unit G 500 G 63 AMG Engine data M 273 KE 55 M 157 DEH 55 LA Rated output at engine speed 6000 5500 Rated torque at engine speed 2800-4800 2000-5000 Compression ratio ε...

  • Page 35: Diesel Engine Om 642

    Diesel engine OM 642 OM 642 With the G 350 BLUETEC, Mercedes-Benz is able to The most important advantages of the BLUETEC tech- demonstrate that the G-Class is also state-of-the-art in nology in the G-Class are: terms of its emissions.
  • Page 36 Diesel engine OM 642 Unit G 350 BLUETEC Engine data OM 642 D30 Rated output at engine speed 3400 Rated torque at engine speed 1600-2400 Compression ratio ε 17.7 P01.00-3366-00 Performance graph OM 642.886 Torque Output Introduction of the New G-Class, Model Series 463 –...

  • Page 37: Engine Cooling

    Engine cooling M 157 AMG To ensure maximum engine power, the engine and The increased performance of the G 63 AMG turbocharger must be cooled optimally. The operating compared to its predecessor, the G 55 AMG, necessi- energy input of the coolant pump was able to be mini- tated modification of the cooling package, which was mized through rigorous prevention of hydraulic pres- adapted to M 157 AMG.

  • Page 38: Exhaust System

    Exhaust system Gasoline engine M 157 AMG The AMG version of the G-Class features an oval, The new firewall catalytic converter is equipped with chrome-plated dual-flow exhaust system on the left two flow-optimized thin-wall ceramic catalytic and right, which is country-specific. It demonstrates converters with AMG-specific monolith coating.
  • Page 39 Exhaust system M 273 OM 642 The exhaust system of the M 273 consists of two fire- The exhaust system of diesel engine OM 642 consists wall catalytic converters which are directly down- of an oxidation catalytic converter, a diesel particulate stream of the left and right exhaust manifold.

  • Page 40: Fuel System

    Fuel system Direct injection of M 157 AMG A spray-guided direct injection system is used on The mechanical fuel pumps are located at the end of engine M 157 AMG. the right cylinder head and are driven by four cams positioned on the camshaft.
  • Page 41 Fuel system M 273 OM 642 The fuel pump suctions the fuel out of the feed module Fuel supply on the OM 642 is carried out by an electric and pumps it through the filter to the fuel distribution fuel pump, which pumps the diesel fuel into the engine rail (single-line system).
  • Page 42 Fuel system Gasoline engine fuel tank The fuel tank has been completely redeveloped in The new fuel tank with in-tank feed module is made order to meet the requirements of engine M 157 AMG entirely out of hot-dip aluminized steel. It also has a in terms of higher and controlled pump output.
  • Page 43 Fuel system Diesel engine fuel tank i Note In addition to the newly developed steel tank of the ® As soon as the AdBlue supply drops to a mini- G-Class, the G 350 BLUETEC is also equipped with a mum, the message "Refill AdBlue" appears on the plastic tank with a volume of 15 liters, for carrying the multifunction display.

  • Page 44: Transmission Data

    Transmission data 7G-TRONIC transmission Automatic transmission oil supply All models are equipped with the familiar 7G-TRONIC The new AMG SPEEDSHIFT PLUS 7G-TRONIC on the automatic transmission with DIRECT SELECT inter- G 63 AMG is also start/stop-capable. This is made face. possible through the use of an electric transmission oil pump for pressure supply when the fixed displace- The AMG SPEEDSHIFT PLUS 7G-TRONIC is used on...

  • Page 45: Introduction Of The New G-Class, Model Series 463 G

    Transmission data Technical data Unit G 350 G 500 G 500/ G 63 AMG BLUETEC convert- G 550 ible Transmission model 722.902 722.904 722.904 722.905 Transmission version W7C 700 W7C 760 Number of gears 7 + 2 R Weight (including converter and 85.5 93.75 transmission fluid)

  • Page 46: Steering

    Steering Steering The G-Class is equipped with an electric longitudinally The steering column tube module is made of an and vertically adjustable steering column as standard. aluminium alloy and weighs just 7.9 kg. The use of the It also features automatic entry/exit steering wheel new steering column tube changes the position of the adjustment, which facilitates access to the driver seat.

  • Page 47: Axles

    Axles Axles The G-Class is equipped with precisely guided and The joint housings have been modified due to the extremely sturdy rigid axles with high twist capabili- different brake calipers on the front axle. ties. They feature trailing arm suspension with The good twisting capabilities of the axles and longer panhard rods and provide traction even in the most spring travels also ensure the best possible ground...

  • Page 48: Suspension

    Suspension Suspension systems The suspension and damping systems are installed High-performance gas-filled shock absorbers also separately from each other and provide excellent off- effectively present jerking of the vehicle. road capability as well as nimble and comfortable A stabilizer bar, which is adjusted to driving perfor- handling on the road.

  • Page 49: On-Road/Off-Road Characteristics

    On-road/off-road characteristics General The suspension of the G-Class is designed for driving The following key figures demonstrate the excellent on demanding terrain. A large ground clearance and off-road characteristics: long spring travels form part of this design. • Maximum gradient of up to 80% on appropriate ground •...
  • Page 50 On-road/off-road characteristics The permanent all-wheel drive also ensures powerful The electronic traction system can brake up to three start-off and acceleration characteristics even in poor wheels with poor ground adhesion and always weather conditions such as rain, ice or snow. precisely apply the engine power to the wheels with the best ground adhesion.

  • Page 51: Brake System

    Brake system Technical data Unit G 350 G 500/G 550 G 63 AMG BLUETEC Front brake system Brake type 4-piston 6-piston fixed caliper fixed caliper Brake disk design Internally ventilated Internally ventilated/ perforated Brake disk diameter Brake disk thickness Pad area 2 x 74 2 x 119.6 Rear brake system...
  • Page 52 Brake system General Internally ventilated brake disks are used on the front With the model refinement, the G-Class has been axle and solid brake disks are used on the rear axle. equipped with a new generation of ESP. Due to the They provide impressively short braking distances, new ESP-Premium brake unit for the new diagonal good response and high thermal durability.

  • Page 53: Wheels And Tires

    Wheels and tires Front light alloy Front tire Rear light alloy Rear tire wheel wheel Code RL3 7.5J x 16 ET63 265/70 R 16 7.5J x 16 ET63 265/70 R 16 7.5J x 18 ET63 265/60 R 18 7.5J x 18 ET63 265/60 R 18 Code RL5 , RL6, RM9...

  • Page 54: Overall Network

    Overall network Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 55 Overall network Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 56 Overall network Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...
  • Page 57 Overall network Network architecture Interior systems A new network architecture is used in model series Most of the systems serve the purpose of basic elec- 463. trical functions e.g. lights, drive authorization and the interior comfort systems. It provides the basis for new, innovative and customer- oriented features such as telematics, driver support A central element of the interior network is the Central systems etc.

  • Page 58: Batteries And Alternator

    Batteries and alternator Batteries and alternator The on-board electrical system is supplied by an alter- The G 63 AMG is equipped with a start/stop function nator. A low-maintenance battery serves as an energy which necessitates a second vehicle battery with store.

  • Page 59: Exterior Lights

    Exterior lights The LED daytime running lamps are integrated in the The headlamp cleaning system is activated automati- headlamp cover. cally every 10th time the windshield is cleaned with the low beams on. The daytime running lamps are automatically switched on or off in the "Auto"...

  • Page 60: Interior Lights

    Interior lights Interior lights Optical fibers in the door side trim and lights in the The standard equipment includes an interior/rear footwell, door openers and center console also light, reading lamps and vanity lamps. The ambiance provide a pleasant lighting mood in the interior illumination, installed as standard, illuminates the compartment.

  • Page 61: Active/Passive Safety

    Active/passive safety Various systems in the G-Class ensure a high level of Trailer stabilization driving safety: ® The new ESP trailer stabilization function can, within • Headlamp Assist with rain and fog sensor the physical limits, prevent "snaking" of a vehicle/ •...

  • Page 62: Restraint Systems

    Restraint systems The following restraint systems, which are coordi- The safety of vehicle occupants has been further nated with each other, help to protect the occupants improved through the use of a new airbag control unit of a G-Class in an accident: and the integration of additional sensor systems.

  • Page 63: Overview Of Systems

    Overview of systems General Blind Spot Assist The new assistance systems of the G-Class include: The Blind Spot Assist system monitors the rear and side areas of the vehicle using short range radar and • DISTRONIC PLUS (SA) warns the driver if another vehicle is detected in the •...

  • Page 64: Climate Control

    Climate control The G-Class is equipped with 2-zone air conditioning "Blow-out sensors" continuously measure the temper- as standard. The new fog sensor, which is located in ature of the air flowing out of the vents. These sensors the cover of the light/rain sensor, provides the air are located on the instrument panel in the outer air conditioning system with important information to vents and in the air vents in the front footwell.

  • Page 65: Telematics

    Telematics With the model refinement, the G-Class has been The following special equipment components are equipped with the New Telematics Generation available: (NTG) 4.5. • Different TV tuners for ECE, Japan and China The "COMAND Online" operating and display system •...

  • Page 66: Sound System

    Sound system Surround sound system ® ® The sound parameters have been adapted based on The harman/kardon Logic 7 surround sound the New Telematics Generation (NTG) 4.5 in combina- system with a 9-channel DSP amplifier (Digital Sound tion with the 17.8 cm (7") color display. Processing) with 450 watts and 14 speakers (power output 9x50 watts) is available optionally (standard in USA).

  • Page 67: Digital Owner's Manual

    Digital Owner's Manual Customer benefits This Digital Owner's Manual enables the customer to Depending on the market variant of the head unit, the find information on operating their vehicle in the customer can call up the required information in up to COMAND Online system.
  • Page 68 Digital Owner's Manual Search functions The Digital Owner's Manual contains several attractive options to search for content. The following options are available: • Keyword search • Visual search • Table of contents Keyword search Keyword search will be familiar to the user from the use of navigation systems.
  • Page 69 Digital Owner's Manual Visual search This multimedia search function guides the customer to the information they require via a 360° view of the vehicle. It can be accessed via the COMAND controller on the center console. P82.87-8605-00 View of visual search P82.87-8606-00 360°...

  • Page 70: Bodyshell

    Bodyshell A ladder-type frame made of sheet steel up to 4 mm The steel frame is cathodic dip painted and powder- thick with closed longitudinal sections and cross coated The cavities are fully treated with hot wax and members forms the basis of the G-Class. This design the vehicle floor is also coated with plastic.

  • Page 71: Abbreviations

    Abbreviations Acceleration skid control Anti-theft alarm system (ATA) Ampere-hour Electronic Stability Program Auxiliary Euro 5 standard (exhaust emission regulation) Brake Assist System Electromagnetic compatibility FE-ATF Controller Area Network Fuel Economy - Automatic Transmission Fluid FSCM Common rail Direct Injection Fuel System Control Module High Definition Carbon dioxide COMAND...
  • Page 72 Abbreviations SDAR New Telematics Generation Satellite Digital Audio Radio Rear Body Controller Thin Film Transistor Special equipment Universal Serial Bus Signal aquisition and actuation module Workshop Information System Selective Catalytic Reduction Introduction of the New G-Class, Model Series 463 – This printout will not be recorded by the update service. Status: 03 / 2012 –...

  • Page 73: Index

    Index ADAPTIVE BRAKE Media Interface ....51 ....14 ®...
  • Page 74 Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart Order No. 6516 1391 02 - HLI 000 000 07 96 – Printed in Germany – 03/2012 – This printout will not be recorded by the update service. Status: 03 / 2012 –...

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